Published: 11-May-2011

2007.0 Range Rover Sport (LS), 303-04D

Fuel Charging and Controls - TDV8 3.6L Diesel

Fuel Injector Balance and Spill Check (G952598)

GENERAL PROCEDURES
  • 19.90.08
  • Injector balance and spill test
  • TDV8
  • 2.00
  • USED WITHINS

Special Tool(s)

E84154

Fuel Injector Spill Test Kit 310-152

E84153

Fuel Return Blanking Caps 310-152-02

WARNINGS:

  • Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

  • The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

  • Do not carry or operate cellular phones when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.

CAUTION:

Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in foreign matter ingress to the fuel injection system.

  1. Disconnect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  2. Remove the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  3. E48702
    Remove the driver side battery compartment lid.
      • Release the 2 clips.
  4. E86050
    Remove the driver side battery compartment side wall.
      • Release the 4 clips.
  5. Remove the driver side battery compartment side wall extension.
  6. E48705
    Remove the driver side battery compartment tray.
      • Remove the 3 nuts.
  7. CAUTION:

    Make sure that all openings are sealed. Use new blanking caps.

    E85153
    Remove the oil level indicator and upper oil level indicator tube.
      • Remove the bolt.
      • Remove and discard the 2 O-ring seals.
  8. E76535
    Remove the RH fuel line shield.
      • Remove the 7 nuts.
  9. Remove the battery tray. For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  10. E85160
    Release the coolant lines.
      • Remove the 2 nuts.
  11. Remove the oil filler cap.
  12. NOTE:

    RH illustration shown, LH is similar

    E76535
    Remove the LH fuel line shield.
      • Remove the 7 nuts.
  13. Install the oil filler cap.
  14. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply lines, the fuel injectors and the fuel rail. For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - TDV8 3.6L Diesel, General Procedures).
  15. WARNING:

    The spilling of fuel is unavoidable during this operation. Make sure that all necessary precautions are taken to prevent fire and explosion.

    E76538
    Disconnect the fuel return line from the LH bank fuel injectors.
      • Remove and discard the 4 fuel return line clips.
  16. E84038
    Blank-off each of the fuel return line ends with blanking caps from the kit.
      • Install the clips.
  17. E87962
    Connect a spill bottle line to each of the injectors.
  18. Install the battery tray.
  19. Install the battery.
  20. Connect the battery positive cable.
      • Tighten the battery positive lead nut to 10 Nm (7 lb.ft).
  21. Connect the battery ground cable.
      • Tighten the battery positive lead nut to 10 Nm (7 lb.ft).
  22. Connect the Land Rover approved diagnostic system to the vehicle.
  23. Run cylinder balance test from 'live data'.
      • Injector balance limits are between 960 and 1.4 k.
      • Note any injector that is outside of these figures (a figure below the limit will usually mean a reduction in fuelling, and a figure above will result in an increase to fuelling).
  24. Start the engine and allow to run for 2 minutes, stop the engine.
  25. CAUTION:

    Do not reject any of the injectors if the spill rates are even but outside of the correct rates shown. The spill rate can be affected by varying fuel rail pressure and fuel temperature. Only suspect a faulty injector(s) if the amount of fuel collected is significantly higher or lower than the others.

    NOTES:

    • The figures shown are to be used as a guide only.

    • A faulty injector could fill a bottle within 2 minutes.

    Observe the spill into bottles, if any bottle starts to fill up quickly stop engine to prevent further spillage.
  26. Disconnect the battery ground cable.
  27. Disconnect the spill bottle lines from the injectors.
  28. Remove the blanking caps from the fuel return line ends.
      • Remove the clips.
  29. CAUTION:

    Make sure the fuel return line clip is correctly installed to the fuel injector before installing the fuel return line.

    E55233
    Connect the fuel return line to the fuel injectors.
      • Install new fuel return line clips.
      • Visually inspect the fuel return line O-ring seals for damage.
      • Apply a light coating of petroleum jelly to the fuel return line O-ring seals.
  30. Carry out steps 14 to 17, step 21 and steps 23 to 29 on the RH bank injectors.
  31. Disconnect the battery positive cable.
  32. Remove the battery.
  33. Remove the battery tray.
  34. Remove the oil filler cap.
      • Remove and discard the O-ring seal.
  35. Install the LH fuel line shield.
      • Tighten the nuts to 5 Nm (4 lb.ft).
  36. Install the oil filler cap.
      • Install a new O-ring seal.
  37. Secure the coolant lines.
      • Tighten the nuts to 10 Nm (7 lb.ft).
  38. Install the battery tray. For additional information, refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  39. Install the RH fuel line shield.
      • Tighten the nuts to 5 Nm (4 lb.ft).
  40. NOTE:

    Remove and discard the blanking caps.

    Install the oil level indicator and upper oil level indicator tube.
      • Clean the components mating faces.
      • Install new O-ring seals.
      • Tighten the bolt.
  41. Install the driver side battery compartment tray.
      • Tighten the nuts to 12 Nm (9 lb.ft).
  42. Install the driver side battery compartment side wall.
      • Secure the clips.
  43. Install the driver side battery compartment side wall extension.
  44. Install the driver side battery compartment lid.
      • Secure the clips.
  45. Install the engine cover. For additional information, refer to: Engine Cover - TDV8 3.6L Diesel (501-05 Interior Trim and Ornamentation, Removal and Installation).
  46. Connect the battery ground cable. For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  47. Disconnect the Land Rover approved diagnostic system from the vehicle.